Modular Furniture System

ABSTRACT

A versatile furniture system including foam support blocks, and may further comprise an outer cover, an inner cover, and/or adhesion system to provide a user with furniture that may be adapted to the users preference.

BACKGROUND

The embodiments herein relate generally to a versatile furniture system.

Conventional mattresses and other furniture items, may not readily adjust for changes in size, weight, or changed preferences of the consumer. Often, when the consumer desires a change in furniture, new items are bought and used ones are discarded. As such, an improved furniture system, which is more versatile, economical, and/or avoids unnecessary waste and expenditure is desirable.

SUMMARY

In accordance with various embodiments, disclosed is a versatile furniture system comprising foam support blocks, which may be of different sizes/shapes/densities to enable a user to create customized furniture/mattress(es) that can grow, change, or adjust to the user's needs. In embodiments, the disclosed system enables the user to disassemble furniture or a mattress item to create a different item or a differently configured item. For example, a user may disassemble a mattress to fashion a couch, or create a larger bed by attaching components or blocks to a smaller bed and/or mattress. In embodiments, a conversion kit may be provided or sold to the user, and may include components that can be attached to the bed/mattress for enabling the consumer to enlarge or change his existing bed for a lower cost than buying a new bed or other piece of furniture.

In embodiments, foam support blocks provide the primary cushioning mechanism and general internal structure. The system may further optionally utilize an outer cover, and inner covers for optimal functionality. Other optional elements may include springs, cooling blocks, fans, heating elements, power outlets, lighting, charging pads, USB outlets, wireless communication systems for sleep recording, sit recording, wired and wireless control modules for smart home functionality, seat adjustment mechanisms, reclining systems, sound systems, etc.

Thus, the disclosed system provides a long-term solution to the existing and changing needs of the customer without sacrificing comfort. Additionally, the disclosed subject matter reduces waste from the furniture/mattress industry by allowing the consumer to reshape and re-purpose their mattress/furniture to their needs. Further benefits and/or advantages of the disclosed system may include: enabling a mattress to be repurposed as different articles of furniture; enabling a mattress to be scaled to make a larger mattress.

BRIEF DESCRIPTION OF THE FIGURES

The detailed description of some embodiments of the invention is made below with reference to the accompanying figures.

FIG. 1. is a top view of a full sized mattress, that displays the overall vertical 75″ dimension, and overall horizontal 54″ dimension. In addition, the orientation of the foam support blocks is displayed, as it can vary depending on mattress size. In the full sized mattress configuration the longer 6″ side of the support block is horizontally aligned, with the shorter 5″ side being vertically aligned. Additionally, in this full sized configuration 15× vertical by 9× horizontal foam support blocks are arranged to scale the blocks to a conventional 75″ vertical by 54″ horizontal full sized mattress.

FIG. 2. is a cut view displaying the internal structure of the full sized mattress. In this view it can be seen that there are 3× layers of foam support blocks of varying densities as identified by the alternating hatch patterns. Additionally, the thickness of the full sized mattress is identified as 9″, with the thickness of each foam support block being 3″. What is not seen in this view is the presence of 3× inner covers encompassing each layer of foam support blocks, and the outer cover encompassing the 3× stacked inner covers with the foam support blocks residing within.

FIG. 3. is a top view of a king sized mattress, that displays the overall vertical 78″ dimension, and overall horizontal 75″ dimension. In addition, the orientation of the foam support blocks is displayed, as it can vary depending on mattress size. In the king sized mattress configuration the longer 6″ side of the support block is vertically aligned, with the shorter 5″ side being horizontally aligned. Additionally, in this king sized configuration 13× vertical and 15× horizontal foam support blocks are arranged to scale the blocks to a conventional 78″ vertical by 75″ horizontal king sized mattress.

FIG. 4. is a cut view displaying the internal structure of the king sized mattress. In this view it can be seen that there are 4× layers of foam support blocks of varying densities as identified by the alternating hatch patterns. Additionally, the thickness of the king sized mattress is identified as 12″, with the thickness of each foam support block being 3″. What is not seen in this view is the presence of 4× inner covers encompassing each layer of foam support blocks, and the outer cover encompassing the 4× stacked inner covers with the foam support blocks residing within.

FIG. 5. is a prospective cut view of a king sized mattress to better display the layout of inner and outer covers and their function within the mattress assembly. During experimentation it was observed that an inner cover was required to maintain the boundary and structural/support between layers of foam support blocks of alternate densities and internal load deflection characteristics. The outer cover serves the function to maintain the overall dimensionality/alignment and orientation of the inner covers and related mattress assembly.

FIG. 6. is a top view of the inner covers with referenced vertical and horizontal dimensions defined by the “Inner Covers Details by Size” table. In addition it can be seen that there is a zipper positioned on the top outer edge of each inner cover, to allow for removal of the inner cover as needed.

FIG. 7. is a side view of a king sized mattress displaying inner cover zipper orientation.

FIG. 8. is a side view of a mattress with the stacked quantity of inner covers being referenced in the “Inner Covers Details by Size” table. In addition, zipper orientation is identified to be on the top outer edge of each inner cover to enable ease of support block removal as needed.

FIG. 9. is a top view of the outer cover with referenced vertical and horizontal dimensions defined by the “Outer Covers Details by Size” table. In addition it can be seen that there is a zipper positioned on the top outer edge of the outer cover, to allow for removal of the outer cover as needed.

FIG. 10. is a side view of a king sized mattress displaying outer cover zipper orientation.

FIG. 11. is a side view of a mattress with the outer cover dimension referenced in the “Outer Covers Details by Size” table. In addition, zipper orientation is identified to be on the top outer edge of each outer cover to enable ease of inner cover and support block removal as needed.

FIG. 12. is a top view of a queen sized mattress, that displays the overall vertical 78″ dimension, and overall horizontal 60″ dimension. In addition, the orientation of the foam support blocks is displayed, as it can vary depending on mattress size. In the queen sized mattress configuration the longer 6″ side of the support block is vertically aligned, with the shorter 5″ side being horizontally aligned. Additionally, in this queen sized configuration 13× vertical and 12× horizontal foam support blocks are arranged to scale the blocks to a conventional 78″ vertical by 60″ horizontal queen sized mattress.

FIG. 13. is a cut view displaying the internal structure of the queen sized mattress. In this view it can be seen that there are 4× layers of foam support blocks of varying densities as identified by the alternating hatch patterns. Additionally, the thickness of the queen sized mattress is identified as 12″, with the thickness of each foam support block being 3″. What is not seen in this view is the presence of 4× inner covers encompassing each layer of foam support blocks, and the outer cover encompassing the 4× stacked inner covers with the foam support blocks residing within.

FIG. 14. is a top view of a twin sized mattress, that displays the overall vertical 75″ dimension, and overall horizontal 36″ dimension. In addition, the orientation of the foam support blocks is displayed, as it can vary depending on mattress size. In the twin sized mattress configuration the longer 6″ side of the support block is horizontally aligned, with the shorter 5″ side being vertically aligned. Additionally, in this twin sized configuration 15× vertical and 6× horizontal foam support blocks are arranged to scale the blocks to a conventional 75″ vertical by 36″ horizontal twin sized mattress.

FIG. 15. is a cut view displaying the internal structure of the twin sized mattress. In this view it can be seen that there are 2× layers of foam support blocks of varying densities as identified by the alternating hatch patterns. Additionally, the thickness of the twin sized mattress is identified as 6″, with the thickness of each foam support block being 3″. What is not seen in this view is the presence of 2× inner covers encompassing each layer of foam support blocks, and the outer cover encompassing the 2× stacked inner covers with the foam support blocks residing within.

FIG. 16. is a top view of a foam support block displaying its 6″ vertical and 5″ horizontal dimensions.

FIG. 17. is a prospective view of a foam support block.

FIG. 18. Is a side view of a foam support block displaying its 3″ thickness.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

In the following detailed description of the invention, numerous details, examples, and embodiments of the invention are described. However, it will be clear and apparent to one skilled in the art that the invention is not limited to the embodiments set forth and that the invention can be adapted for any of several applications.

In accordance with various embodiments, disclosed is a furniture system comprising foam support blocks, which may interlock to adjust or change the size and/or functionality of a furniture item. In embodiments, the disclosed system may further comprise foam support blocks, an adhesion system, an outer cover, and/or inner covers.

With reference to the accompanying figures, the foam support blocks of the disclosed system serve as the primary support mechanism of the furniture/mattress system; these are the essential components that the consumer may manipulate and/or readjust to their comfort or needs. The blocks may come in different sizes and shapes depending on the consumer's needs. For example, the consumer may originally purchase a basic kit for a specific furniture item (e.g., a queen sized mattress) which may include all materials necessary for that item, and may subsequently purchase an add-on kit that enables the original item to be changed (e.g. the queen mattress may be changed to a couch via the add-on kit). In embodiments, the add-on kit may provide different quantities of different density/type/deflection foam support blocks all of which the consumer can customize depending their preference or needs. For example, the add-on kit may provide additional blocks, which may be hard, soft, and/or different dimensioned blocks.

In embodiments, the foam support blocks may offer a selection of different materials, fabrics, thread counts, water resistance/proofing quality, patterns, washability, color, function, made from recycled materials, anti-microbial, etc. depending on such factors as the consumer's design and comfort preferences, needs, technological advances, etc.

In embodiments, the disclosed adhesion/connection system functions to hold the foam support blocks together, and may further function for distributing the load of the blocks. The adhesion/connection system may comprise connection elements which may either be directly attached (i.e. integral) to the blocks themselves, to a portion of the blocks, and/or provided as separate components for attachment to the blocks. The adhesion system may be chemical and/or mechanical in nature, and may utilize, for example, Velcro, glue, buttons, static forces, zippers, friction, compression, tension, magnets, plastic loop sheets, foam pin, adhesives, buttons, clasps, hooks, suction elements, interlocking tables, and/or other interlock mechanisms which may be or may become available with emerging technology.

In embodiments, the outer cover system may comprise an outer cover that retains the internal blocks and sub-components according to their outer three-dimensional shape and/or creates the outward appearance of the furniture item. The outer cover may further function to provide the dimensional consistency needed for readily available consumer add-on products like sheets, comforters, etc. For example, the outer cover for a mattress may be rectangular with its size dependent on the size of mattress; or the outer cover for a couch may be dimensionally similar to most commercially available couches; the same can be said for chairs, and the like. The outer cover may be made of commercially available materials, such as Nylon, cotton, wool, vinyl, and the like, with the primary function being to protect, cover, personalize, and assist in maintaining product shape. In embodiments, the outer cover may be customizable in terms of material, fabric type, thread count, water resistance/proofing, patterns, color, washability, function, etc. As such, the consumer may easily change the color, fabric type, and/or overall outer appearance of a furniture item, such as a couch, without changing the underline structure of the couch.

The inner covers may be made out of any sheeting material, with the primary purpose to aid in distributing loads through the multi-layer foam support block system. The unit is then sold as a kit to consumers, including all or parts of the system as mentioned above. The consumer will then build the kit to suit their needs, with add on kits available for purchase to customize or re-purpose the originally purchased kit. All add on kits will be for sale only through this patent owner, and subs-contracted entities, with the contracts being made with the patent originator.

In embodiments, the inner covers may serve to take the loads from the layer of foam support blocks above and distribute it to the foam support blocks below, and may further serve to simplify the foam block building system allowing the consumer to build one layer at a time effectively simplifying the process. In embodiments, the inner covers may also attach to the blocks in contact with the inner covers to help keep the blocks in place, as well as aid or serve the same purpose as the outer cover. The inner covers may also be customizable depending on material, fabric type, thread count, water resistance/proofing, patterns, color, washability, function, etc. The inner covers may replace the adhesion system, and/or Outer cover, according to various embodiments.

Together the foam support blocks, adhesion system, outer cover, and/or inner covers provide a completely modular furniture system, capable of adapting to the consumer's needs by allowing the consumer to “build” the furniture as they see fit utilizing the foam support block architecture. The foam support blocks may be moved around to create alternate furniture pieces, that may or may not be used in conjunction with different outer covers, according to various embodiments.

The invention may be produced utilizing foam support blocks sourced from either a mass producer or in-house process. The foam support blocks may be cut to size using various commercially available methods and/or methods which may become available with emerging technology. Additionally, the foam support blocks, outer cover, adhesion system components, and/or inner covers, may be returned to the producer once the pieces are damaged or worn beyond repair, to be recycled and reused in future products.

According to an exemplary embodiment, the consumer may purchase a basic kit for a specific item (e.g. king mattress, queen mattress, full mattress, twin mattress, couch, chair, etc.). The kit may include all components for the particular item. Thereafter, if the consumer desires to change the size or function of the kit they may purchase an add-on or repurpose kit with the necessary components to re-purpose their basic kit, e.g. turn their bed into a couch or other piece/pieces of furniture). The consumer may then build the basic kit and/or add on components from the add-on kit/repurpose kit following building instructions on generalized comfort configurations, or go completely custom to fit their comfort levels. In embodiments, a kit may include extra foam support blocks of various densities, stiffness, and other comfort associated qualities. For example, a mattress kit may include extra foam support blocks of varying stiffness, density, etc. to allow for the customer to swap more rigid/dense blocks for ones with a softer feel, or vice versa, based on their desired comfort.

Besides home furnishings, the disclosed system may also be used in transportation and recreation sectors, or any other industry that utilizes beds or seating. It can also be used in the maternity and conception industry to help with birth or conception.

Persons of ordinary skill in the art may appreciate that numerous design configurations may be possible to enjoy the functional benefits of the inventive systems. Thus, given the wide variety of configurations and arrangements of embodiments of the present invention the scope of the invention is reflected by the breadth of the claims below rather than narrowed by the embodiments described above. 

What is claimed is:
 1. A versatile furniture system comprising foam support blocks, and further comprising an outer cover, and/or inner covers, and/or adhesion system. 